Coreless paper roll manufacturing method
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Solution Overview
Problem
In the production of coreless roll paper, the extraction of the winding shaft often results in deformation of the inner solidified layer, particularly when a grooved winding shaft is used, making it difficult to maintain both the strength of the core and ease of separation of the tissue material layers.
Innovation Solution
A method involving a winding shaft with gear-like grooves and a cover member, where the paper is wound on the cover member, allowing the shaft to be extracted with the cover member left in the roll paper, which is then removed, thereby protecting the center hole and preventing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a grooved winding shaft is used to enable easy separation of tissue material layers, then the ease of operation is improved, but the inner solidified layer strength deteriorates causing deformation during shaft extraction
Solution Approach 1:
A cover member is introduced as an intermediary component between the grooved winding shaft and the tissue material. The cover member has a smooth outer circumferential surface that contacts the tissue material, preventing it from entering the grooves of the shaft. This mediator allows the shaft to have grooves for easy separation while maintaining sufficient strength during extraction.
Solution Approach 2:
The winding shaft is segmented into two functional parts: the grooved body part that provides separation capability, and the smooth cover member that provides structural support during extraction. This segmentation allows each part to fulfill its specific function without compromising the other.
2Ease of operation
If the tissue material is loosely wound to enable easy separation of layers, then the ease of operation is improved, but the inner solidified layer strength deteriorates
Solution Approach 1:
The cover member acts as a mediator that allows loose winding of tissue material while maintaining strength. The smooth surface of the cover member provides uniform support, preventing the tissue material from directly contacting the grooved shaft and entering the grooves, thus maintaining both loose winding and structural integrity.
3Strength
If adhesive is applied extensively to maintain inner solidified layer strength, then the strength is improved, but the ease of separation of tissue material layers deteriorates
Solution Approach 1:
Adhesive application is localized to specific areas rather than being extensive. The cover member provides structural support, allowing adhesive to be applied only where needed to bond the tissue material to the cover member, rather than requiring extensive adhesive coverage throughout the inner solidified layer.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables stable production of coreless roll paper by preventing the winding-start end from being pulled out during shaft extraction, ensuring the inner solidified layer maintains sufficient strength while allowing easy separation of tissue material layers.
Implementation Method 1
the cover member is put on and fixed to the body part... the paper is wound on the cover member... preventing the winding-start end from being pulled out during shaft extraction
Data Source
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AI summary
A method for producing coreless roll paper includes a winding step in which paper 11 is wound on a shaft 20 in a roll shape, and an extracting step in which the shaft 20 is extracted from roll paper 12 to form a center hole 13. The shaft 20 includes a body part 22 having grooves 23, and a sleeve 30 is put on and fixed to the body part 22. In the winding step, the paper 11 is wound on the sleeve 30.